Prestressing fixture to eliminate automotive p.s.i.r. door-chute vibration weld visibility

Abstract

An automotive interior component including an airbag chute having at least one weld bar, and a pre-stressed instrument panel having a substrate layer for bonding to the weld bar. The pre-stressing provides tensile stress at weld bar bonding areas to reduce any deformation visible on an exposed surface of the instrument panel.

1 . An automotive interior component comprising:
 an airbag chute having at least one weld bar; and   a pre-stressed instrument panel having a substrate layer for bonding to the weld bar,   wherein tensile stress at weld bar bonding areas in the pre-stressed instrument panel reduces any deformation visible on an exposed surface of the pre-stressed instrument panel due to shrinkage of weld melted instrument panel material.   
   
   
       2 . An automotive interior component according to  claim 1 , wherein the weld bar of the airbag chute is vibration welded to the substrate layer. 
   
   
       3 . An automotive interior component according to  claim 1 , further comprising a cover layer bonded to the substrate layer. 
   
   
       4 . An automotive interior component according to  claim 3 , wherein the cover layer is made of one of polyvinyl chloride and ThermoPlastic Olefin. 
   
   
       5 . An automotive interior component according to  claim 3 , wherein the cover layer is about 0.4-1.0 mm thick. 
   
   
       6 . An automotive interior component according to  claim 1 , further comprising a cover layer and an intermediate foam layer bonded to the substrate layer. 
   
   
       7 . An automotive interior component according to  claim 6 , wherein the foam layer is made of polypropylene. 
   
   
       8 . An automotive interior component according to  claim 6 , wherein the foam layer is about 0.5-3.0 mm thick. 
   
   
       9 . An automotive interior component according to  claim 1 , wherein the substrate layer includes thermoplastic polymers. 
   
   
       10 . An automotive interior component according to  claim 1 , wherein the substrate layer is about 2.0-4.0 mm thick. 
   
   
       11 . An apparatus for manufacturing a pre-stressed automotive instrument panel for eliminating distortion in an area of vibration welded airbag chutes, said apparatus comprising:
 a weld fixture including a plurality of convex pre-stressors disposable against an instrument panel for creating compression in an area of contact with an instrument panel and creating tension in a surface opposite the contact area upon application of vacuum to draw the instrument panel toward the weld fixture.   
   
   
       12 . An apparatus according to  claim 11 , wherein the weld fixture is disposable against a cover layer of the instrument panel and creates tension in a substrate layer of the instrument panel, the substrate layer being disposed adjacent an opposite face of the cover layer with or without an intermediate foam layer being disposed between the cover and substrate layers. 
   
   
       13 . A method of manufacturing an automotive instrument panel for eliminating distortion in an area of vibration welded air bags, said method comprising:
 providing a weld fixture including a plurality of pre-stressor protrusions;   placing the pre-stressor protrusions against an instrument panel;   generating a force to press the weld fixture against the instrument panel to create compression in an area of contact of the weld fixture with the instrument panel and tension in a surface opposite the contact area; and   vibration welding an air bag chute to the instrument panel such that a weld bar of the air bag chute is welded to the surface placed in tension.   
   
   
       14 . A method according to  claim 13 , the instrument panel further comprising a substrate layer, a foam layer attached to the substrate layer, and a cover layer attached to the foam layer,
 wherein placing the pre-stressor protrusions includes placing the pre-stressor protrusions against the cover layer of the instrument panel, and   wherein vibration welding further comprises vibration welding an air bag chute to the substrate layer.